PROCESSING AND TECHNICAL DATA

Simply original, originally simple

PROCESSING AT A GLANCE

PROCESSING METHODS JOINTING / FIXING TECHNIQUE

Sawing see page 5 Riveting see page 14

- vertical panel saw, - using commercially available
circular saw or jig saw tool and blind rivets, fastening
possible in 1 mm cover sheet

Routing see page 6 Screwing see page 17

- CNC machining centres and - with sheet metal screws, rivet
circular panel saws bolts and nuts fastening possible
in 1 mm cover sheet

Drilling see page 6 Glueing see page 19

- drill bits with locating point - adhesive sealing compounds
for thin sheets
Indoor use:
- large holes with countersinks
- metal adhesives
and counterbores
- double-sided adhesive tape

Pressing see page 6 SURFACE TREATMENT

- bending press

Lacquering see page 20

- overlacquering of ALUCORE ®
Bending see page 7 surfaces with suitable lacquer
- roll bending machines qualities
- step-bending with bending press

Printing see page 20

Folding see page 8 - on polyester lacquer surfaces
- routing and folding technique with commercial printing inks
or with bending press

Panel edgings see page 11 Laminating see page 20

- by folding cover sheets or - with self-adhesive foils
using panel edging sections

Edition 2  ALUCORE® Processing and Technical Data  GB

CONTENTS

TRANSPORTATION, STORAGE
4 General

PROCESSING METHODS
5 Sawing
6 Routing
6 Drilling / Countersinking
6 Pressing / Stamping
7 Bending

FOLDING TECHNIQUES
8 General
9 Machines
10 Tools

EDGING
11 Folding the cover sheet
12 Edge bands
12 Filling and contour-cutting the edges
12 Edging sections
13 Panel edging sections

JOINTING / FIXING TECHNIQUE
14 General
14 Rivets
17 Threaded fasteners
19 Glueing
19 Clamp connections

SURFACE TREATMENT
20 Lacquering
20 Printing
20 Laminating

CLEANING AND MAINTENANCE

21 General
21 Cleaning agents

TECHNICAL DATA
22 ALUCORE ®

22 ALUCORE ® base

INFORMATION
23 Information

Edition 2  ALUCORE® Processing and Technical Data  GB

 TRANSPORTATION, STORAGE

GENERAL
To protect ALUCORE ® composite panels against mechanical ­d amages
1.00 m – 1.20 m and the harmful effects of weather conditions and moisture, the following
information must be observed:
-- The pallets must be handled carefully during transport and unloading.
(Caution: Do not handle open pallets).
Set maximum fork width -- Upon delivery the pallets must be examined for any damage due to
transportation and moisture
-- ALUCORE ® panels that have become wet must be dried to avoid any
spots or corrosion forming. Any damage must be reported immediately
and confirmed by the forwarding agent.
-- Store the pallets so that they are protected against any wetness penet-
rating due to rain and spray water and avoid any condensation forming
(e.g. when transporting cold panels to warmer rooms).
Pick up the pallet, slightly raise the fork -- Store the pallets stacked one over the other (do not store ­A LUCORE ®
panels standing vertically) with a maximum of 6 pallets of the same
format stacked on top of each other (heavy pallets at the bottom).
-- Individual panels must be lifted off the pallet by two people holding all
four corners and not drawn over each other. Carry the panels ­vertically.
Wear gloves to avoid staining.
-- When stacking panels, nothing should be put in between to avoid
markings.
Pick up the complete pallet, do not draw
nor push
To ensure perfect functioning of the ALUCORE ® protective film, the fol-
lowing information should be observed:
-- Storage exceeding 6 months should be avoided. Severe temperature
fluctuations and exposure to direct sunlight reduce the long-term
durability. In this case the protective film may become very difficult
to remove.
-- Do not mark the protective film with inks (markers), tapes or labels.
Solvent or plasticizer may penetrate the film and affect the lacquered
surface.
-- Should the protective film partially come off during processing or after
assembly, dirtied edges can occur in the course of time, which may
be difficult to remove.
-- Remove the protective film as soon as possible after assembly.
­P rotective film that remains on the panels for an extended period of
exterior exposure may be very difficult to remove.
-- Make sure not to remove the protective film at temperatures below 10° C.

4 Edition 2  ALUCORE® Processing and Technical Data  GB

PROCESSING METHODS

SAWING

Carbide tipped (CT) saw blades

Blade geometry Tooth thickness approx. 2 - 4 mm,

tapered to the side to prevent jamming

Tooth geometry trapeze tooth / flat tooth

Pitch t 10 – 12 mm
Clearance angle α 15°
Rake angle γ 10° positive

Maximum cutting speed v 5,000 m/min

Maximum feed s 30 m/min

Carbide tipped (CT) saw blades for HOLZ-HER and

Striebig circular panel saws

Trapezoid / flat tooth saw blades, flat teeth 45° chamfered Jig saw blades
for burrfree edges For wood or plastics, e.g. T101 B (Bosch),
tooth thickness 2.5 mm Carbide tipped (CT)
Saw blade Ø D = 300 mm saw blades for precision cuts

(for Striebig panel saw Standard II)

Number of teeth Z = 72
LEUCO-Code No. 181724

Saw blade Ø D = 250 mm

(for Holz-Her panel saw 1255 ALUCOBOND®)
Number of teeth Z = 60
LEUCO-Code No. 181726

Bore Ø d = 30 mm
Tooth thickness 3.2 mm
Clearance angle 15°
Rake angle 10° positive

Manufacturer / Supplier LEUCO
Ledermann GmbH & Co. KG
www.leuco.com

Sketch showing edge geometry for professional resharpening

Edition 2  ALUCORE® Processing and Technical Data  GB 5

 PROCESSING METHODS
Single flute cutter with right hand twist
Countersinks are used for countersinking
pre-drilled holes and for drilling out bigger
holes through ALUCORE ®.
Flush joint with H section
Flush edging with lining section
Overlapping panel joint
6 Edition 2  ALUCORE® Processing and Technical Data  GB
ROUTING
ALUCORE ® can be easily routed on conventional routing machines and
CNC machining centres. To avoid pressure marks on the surface, please
use plastic or wood vice jaws when chucking the workpieces. The cutters
for aluminium and plastics are also suitable for ALUCORE ®.
Suitable end milling cutters for ALUCORE ® :
- Carbide tipped cutter Series F 113
Manufacturer / Supplier
GIS Gienger Industrieservice
www.gis-tec.de
DRILLING / COUNTERSINKING
ALUCORE ® can be drilled with twist drills normally used for aluminium
and plastics. Drilling without burr is possible using the following drills:
- Spot facing cutter with centre-point. e.g. Extreme 2 TM HSS-G metal
drill DIN 338 of De WALT, Idstein, Germany
- stainless steel drills HSS cobalt DIN 338
PRESSING / STAMPING
ALUCORE ® composite panels can be pressed. The core is compressed
without destroying the viscoplastic bonding system. This offers new
processing and application possibilities. For more information, please
refer to the separate leaflet “Pressing ALUCORE ® composite panels".
Adapter Adapter
Support Support
Upper die plate Upper die plate
Lower die plate Lower die plate
Die Die
PROCESSING METHODS

BENDING WITH A ROLL BENDING MACHINE

ALUCORE ® composite panels of 6 and 10 mm thickness can be bent
using three and four-roll bending machines with relatively close radii.
The viscoplastic composite system enables radii to be produced from
300 mm with a panel thickness of 6 mm and from 700 mm with a panel
thickness of 10mm. The minimum diameter of the rolls should be 150 mm.

Bending with a roll bending machine

The values for adjusting the rolls have to be determined by trial. The
bending rolls must be thoroughly cleaned of swarf before processing
ALUCORE ®.

The surface should be protected from damage by affixing plastic strips Die
of 1 - 2 mm thickness during processing.

STEP-BENDING WITH BENDING PRESSES

ALUCORE ® can be shaped using the step-bending process. The bending
Plastic support
radius is determined by the stamping depth t, the stamping distance s
and the panel thickness d. Please ask for details. Die plate

Step-bending process

BENDING WITH SAW CUTS

ALUCORE ® can be bent by applying saw cuts on the rear side of the
b
panel. The required radius r a is determined by the tooth thickness s, the s d
wall thickness b, the panel thickness d and the number of saw cuts.
1.3

The saw cuts are carried out using the recommended saw blades. To
obtain a final thickness of 1.3 mm, corresponding tracing rollers are at-
tached to the saw blades of the vertical panel saws. Principally, bending
should take place in the 1 mm thick cover sheet.
a
r

Edition 2  ALUCORE® Processing and Technical Data  GB 7

 FOLDING TECHNIQUES

Panel Bending Material Folding

thickness radius outside gain height min.
GENERAL
(mm) (mm) (mm) (mm) Folding with the bending press
6 ~4 2.7 20 ALUCORE ® can be folded on bending presses using the tool geometry
10 ~9 5.0 25 shown in the sketch. When measuring cuts, the material gain for the
15 ~13 7.5 35
corresponding thickness must be taken into consideration when making
20 ~16 8.5 50
90° folds.
25 ~18 10.0 60

Routing and folding technique / producing corners and edges

Corners and edges can be produced simply on ALUCORE ® panels using
Die

10°
the routing and folding technique. With all versions, a groove is routed
on the rear of the panel into the 1 mm thick cover sheet at the front.

1.5
Polyethylene In version 1, as with ALUCORE ®, a cutter disk or forming cutter for
film
V-grooves 90° is used in the appropriate width.

Die plate
In version 2, the core of the panel is pre-cut using special tools. The
≥ 85° grooves can be produced with CNC machining centres. Normally,
folding by hand is possible. If this is not possible, we recommend the
Folding with the bending press use of a folding machine.

version 1 version 2

Tracing roller for exact groove-depth Tracing roller for exact groove-depth
adjustment adjustment

Cutter disk Cutter disk for

for V-groove rectangular groove

ALUCORE ® ALUCORE ®

Important:
These are customized design tools
to match the respective machine and
can be ordered by the processor from
the recommended manufacturers.
Please state the tooth geometry,
tool diameter, etc.

8 Edition 2  ALUCORE® Processing and Technical Data  GB

FOLDING TECHNIQUES

MACHINERY FOR ROUTING AND FOLDING TECHNIQUE

Vertical panel saws ALUCOBOND ® / ALUCORE ® routing device
(customized accessory)
For V-shaped grooves of up to 10 mm panel thickness and for rectangular
grooves Holz-Her Vertical panel saw PK 1255 ALUCOBOND ® ; Striebig
vertical panel saw Standard II for composite panels.
Manufacturers / Suppliers
Reich Spezialmaschinen GmbH Striebig AG Maschinenbau
www.holzher.de www.striebig.com

Other panel saws can subsequently be provided by the above manufac-

turers with an additional routing device. Please ask for details.

Vertical panel saws

CNC machining centres

With large panel thicknesses such as 10 mm, V-grooves cannot be pro-
duced with vertical panel saws (cutter edge width max. 20 mm). CNC
machining centres are used for this purpose. Rectangular grooves can
also be produced on CNC machining centres. Please ask for manufac-
turers of CNC machining centres.

Edition 2  ALUCORE® Processing and Technical Data  GB 9

 FOLDING TECHNIQUES

TOOLS FOR ROUTING AND FOLDING

The following points must be taken into consideration:
- The edges should not be bent back and folded a second time.
- The width of the base cutter edge must be 2 mm.
- The grooves should basically be routed in the 1 mm thick cover sheet.
- After routing the remaining metal sheet must be 0.8 mm thick.

Cutter disk for V-grooves 90°

For panel thicknesses of 6 and 10 mm a milling cutter for 90° V-grooves
with a cutter edge width of 20 mm must be used on circular panel saws.
Customized design by Speiser.
Supplier for cutter disks for V-grooves and special saw blades
Cutter disk for V-grooves 90°
Speiser Werkzeugvertriebs-GmbH
www.speiser-werkzeugtechnik.de

End milling cutter for V-grooves 90°

With cylindrical shank of the corresponding diameter for all panel thick-
nesses. Customized design by KWO.
Supplier for end milling cutters
KWO-Werkzeuge GmbH
www.kwo.de

Milling cutter for rectangular grooves for ALUCORE ® 10 mm with

additional pre-cutter for ALUCORE ® 15, 20 and 25 mm
Instead of the milling cutter for rectangular grooves a special saw blade,
as shown on page 11, may also be used. Customized design by OERTLI.
Please ask for details.
Supplier for cutter disks for rectangular grooves and for pre-cutters
OERTLI Werkzeuge AG
www.oertli.ch
End milling cutter for V-grooves 90°

Cutter disk for

rectangular grooves
Pre-cutter

Tracing roller

Panel thicknesses
25
20
15
10

2
14
19 Groove widths
24
29

Milling cutter for rectangular grooves

10 Edition 2  ALUCORE® Processing and Technical Data  GB

EDGING

Tracing roller Saw blade

PRODUCING EDGINGS BY FOLDING THE COVER SHEET
Routing the panel by means of a special saw blade
Carbide tipped saw blade, tooth geometry, trapeze tooth (customized
design by Speiser)
Bore ø d = 30 mm
Saw blade ø D = 244 ± 0.05 mm With 6 and 10 mm thick ALUCORE ® panels
Number of teeth z = 40 routing is generally carried out in the 1 mm
thick cover sheet.
Tooth thickness = 3.2 mm
Clearance angle = 15°
Rake angle = 10° positive
Width of base cutter
at trapeze tooth = 2 mm
Supplier
Speiser Werkzeugvertriebs-GmbH, www.speiser-werkzeugtechnik.de
Tracing roller

Depending on the saw blade diameter and the panel thickness, a cor-
responding tracing roller, as with the routing and folding technique for
ALUCOBOND ®, is required to keep the precise routing depth (remaining
sheet thickness 0.8 mm). After routing the panel, the honeycomb core
and the rear cover sheet are cut off using a joint cutter.

Routing the panel with a cutter disk for rectangular grooves

A further possibility for preparing the panel edging for cover sheet
folding is routing using a cutter disk for rectangular grooves. For panel
thicknesses of 15, 20 and 25 mm a pre-cutter or a joint cutter is used to Special saw blade

remove the remaining core.

ALUCORE ®

Folding the edges of the cover sheets

We recommend folding the edges of the cover sheets with a folding
machine as better results are obtained using this method.

Types
Joint cutter
Oscillating joint cutter, Super Cut, Type FSC 2.0 Q
Cutter
Straight form
Supplier
C. & E. Fein GmbH
www.fein.de
Dimension to be set

Calculating the dimension to be cut

Dimension to be cut
Depending on the type of edging, the panel thickness is added to the
final width or length, and the thickness of the cover sheet of 1 mm is
then deducted. Final dimension

Dimension to be set on the panel saw

Example: Dimension to be cut 814 mm
Desired final dimension 800 mm Less panel thickness -15 mm
+15 mm Less 1 mm thickness
-1 mm of cover sheet -1 mm
Dimension to be cut = 814 mm = Dimension to be set = 798 mm

Edition 2  ALUCORE® Processing and Technical Data  GB 11

 EDGING

PRODUCING EDGINGS BY MEANS OF EDGE BANDS

ALUCORE ® edges can be closed decoratively by filling them with
melamine resin and applying edge bands.

PRODUCING EDGINGS BY FILLING AND CONTOUR-CUTTING THE

EDGES
Edgings can also be produced by filling the ALUCORE ® edges with
plastic material and subsequently cutting the contour of the edges by
means of end milling cutters. With this method, the cover sheets can be
routed visibly or the ALUCORE ® edges are filled with plastic material
protruding over the edges and then cut or ground.

PRODUCING EDGINGS USING EDGING SECTIONS

An optically attractive edging can be produced by routing the edges of
ALUCORE ® panels with a disk milling cutter and subsequently inserting
edging sections.

Aluminium edging sections are available for all panel thicknesses.

Prior to inserting the sections, a bonding agent is filled into the grooves
to secure them. The bonding agent firmly fixes to the honeycomb core
Edging sections and section teeth, thus preventing the sections from slipping out.
Metall Josten GmbH & Co. KG
www.mejo.de
Bonding agent
Fix All Crystal – Permanently elastic, transparent structural adhesive
Supplier
SOUDAL
www.soudal.com
Disk milling cutter
for grooves
Cutting the groove
A disk milling cutter and a hand routing machine or CNC machining centre
are used to cut a groove into the core at the ALUCORE ® edges:
Carbide tipped disk milling cutter for grooves
Diameter D = 40 mm
Width of edge B = 2.5 mm
Mandrel Bore ø d = 6 mm, Reference No. 37329
Cutter mounted on a mandrel
with ball bearing
Shank ø 6 mm, Reference No. 37910
Shank ø 8 mm, Reference No. 37912
For better guidance a second ball
bearing is required
Ball bearing ø 19 mm, Reference No. 00504
Supplier
KWO-Werkzeuge GmbH
www.kwo.de

Hand routing machine

12 Edition 2  ALUCORE® Processing and Technical Data  GB

EDGING

PRODUCING EDGINGS USING PANEL EDGING SECTIONS

Depending on the type of application, edging sections of various shapes
can be attached to the ends of the ALUCORE ® panels. They are fixed to
the panel by bonding, clamping or riveting to the cover sheet.

Examples

For sections please ask for details.

Edition 2  ALUCORE® Processing and Technical Data  GB 13

 JOINTING / FIXING TECHNIQUE

GENERAL
ALUCORE ® can be joined by means of standard processes used in metal
and plastics technology. If ALUCORE ® is to be joined to structural parts
of metals other than aluminium, or if fasteners (e.g. bolts, screws) are to
be used, the following material guidelines should be observed:
- Fasteners and structural parts made of aluminium, plastic or stainless
steel should be suitable for assembly with ALUCORE ®.
- When using other materials please insert insulating washers or apply
protective a coating to prevent corrosion.
- Please take the thermal expansion of the panel into account for outdoor
use of ALUCORE ® to avoid jamming or deformation.
- The minimum gap depends on the expected expansion of the panel.
- Please refer to processing recommendations for rivets and bolts for
additional measures to prevent jamming.
- The linear thermal expansion of ALUCORE ® is determined by the
aluminium cover sheets.
At a temperature difference of 100°C the longitudinal deformation
is 2.4 mm/m length/width.

RIVETS
Rivets - not penetrating the panel
Rivets generally must be anchored in the 1 mm thick ALUCORE ® cover
sheets Sections can be attached to ALUCORE ® with commercially
available rivets for aluminium constructions. After drilling a blind hole
of the same diameter as the rivet shank, the rivets can be anchored in
the cover sheet. As a rule, rivets with stainless steel mandrel are used.

Blind rivet with panhead Expansion blind rivet Blind rivet with countersunk head
For ALUCORE ® with a thickness For ALUCORE ® with a thickness
of 10 mm or more of 6 mm or more

Rivets - penetrating the panel

ALUCORE ® panels can be joined together or fastened to other materials
using rivet types commercially available for aluminium constructions.
For outdoor use and for use in areas of high humidity, aluminium blind
rivets with stainless steel mandrels are normally used to prevent ugly
corrosive edges. When using aluminium blind rivets with steel mandrels,
the mandrel should drop out after riveting (detachable version).

14 Edition 2  ALUCORE® Processing and Technical Data  GB

JOINTING / FIXING TECHNIQUE

For outdoor use please note:

-- Use aluminium blind rivets that have been approved for construction
with a 5 mm shank diameter and an attachment head diameter of
11 or 14 mm.
-- Please take the thermal expansion of the panel into account (2.415 mm/m/
  

100°C). To avoid jamming, the hole in the panel must be large enough
to allow for expansion.
-- With the shank of the rivet fitting closely to the edge of the hole, the Distance min. 15 mm,
attachment head must cover over 1 mm of the area surrounding the hole. countersunk rivets are not suitable
-- Hole gauges are used for centrically drilling holes into the panel and
the substructure and for centrically fitting the rivet.
-- Rivet attachment jigs are used for fitting blind rivets without jamming
allowing for a tolerance of 0.3 mm. Make sure to use rivet attachment
jigs and rivets from the same manufacturer, as the height of the at-
tachment head according to DIN 7337 may vary.
-- The clamping thickness results from the thickness of the material to
be riveted plus an additional value of 2 mm to ensure that the closing
head is perfectly formed. In accordance with this clamping thickness
the corresponding shaft length is determined in the tables provided
by the rivet manufacturers.

Important:
During riveting, many factors may have an influence on the exact tolerance
of the rivets of 0.3 mm (e.g. rivet head tolerance). We therefore recom-
mend that you make a test on a façade panel. Please always remove the
protective foil around the riveting area prior to riveting.

Blind rivet nuts and bolts

Blind rivet nuts and bolts are threaded elements performing the function
of a blind rivet and a nut or bolt (screw).

There are various types of rivet head and materials which can be selec-
ted depending on the intended application. The blind rivet nuts or bolts
are inserted in blind holes drilled in one side of the ALUCORE ® panel.
Subsequent fitting with a tool is fast and cost-effective.

Due to the minimum shaft length of 11 mm these fixtures can only be
used for a panel thickness of 15 mm or more. As a rule, the rivet must
be anchored in the 1mm thick cover sheet.

Edition 2  ALUCORE® Processing and Technical Data  GB 15

 JOINTING / FIXING TECHNIQUE
Tool for rivet nuts / bolts
Manufacturer / Supplier
Rivet nuts/bolts and appropriate
tools
HONSEL
Umformtechnik GmbH
www.honsel.de
Böllhoff GmbH & Co. KG
Verbindungs- und Montagetechnik
www.boellhoff.de
Gebr. Titgemeyer GmbH & Co. KG
www.titgemeyer.de
Gesipa-Blindniettechnik GmbH
www.gesipa.de
16
Blind rivet nuts Blind rivet bolts
Rivet head
Screw thread
Bolt head
Rivet shaft with nut thread
Rivet shaft
Types of rivet head Types of rivet head
Panhead
Panhead
Countersunk head
Countersunk head
Small countersunk head
Suppliers / Manufacturers
Blind rivets
Commercially available or from
GESIPA-Blindniettechnik GmbH
www.gesipa.com
Gebr. Titgemeyer GmbH & Co. KG
www.titgemeyer.de
VVG-Befestigungstechnik GmbH & Co
www.vvg-befestigungstechnik.de
Blind rivets lacquered
MBE GmbH
www.mbe-gmbh.com
SFS intec GmbH & Co. KG
www.sfsintec.biz
Plastic covers for rivets
HA-WI
Kunststoffe GmbH & Co. KG
www.ha-wi.com
Hole gauges
Please refer to blind rivets lacquered: MBE GmbH
Rivet attachment jigs
Appropriate rivet attachment jigs are available from manufacturers or
suppliers of rivets.
Edition 2  ALUCORE® Processing and Technical Data  GB
JOINTING / FIXING TECHNIQUE

THREADED FASTENERS
Threaded fasteners for outdoor use
Please take the thermal expansion of the panel into account when using
threaded fasteners outdoors. To avoid jamming, the hole diameter in the
panel must allow for the expansion. Fastening without jamming is possible
with fascia screws made of stainless steel with sealing washer that have Distance min. 15 mm

been approved for construction. The screws must be suitable for the Fascia screw, thread-cutting
corresponding substructure (please note the information given by the
manufacturer). The screws should be tightened with a torque wrench or
screw driver so that the sealing washer is placed on the panel for sealing
the bore hole without exerting pressure onto the panel. Hole gauges are
used for centrically drilling holes into the panel and the substructure and
for centrically fitting the rivet.
Important:
Please always remove the protective foil prior to screwing. Hexagon screw

Suppliers / Manufacturers
Fascia screws
EJOT Baubefestigungen GmbH
www.ejot.de

Fascia screws, lacquered

MBE GmbH
www.mbe-gmbh.com
Carriage bolt

SFS intec GmbH & Co. KG

www.sfsintec.biz

Hole gauges
please refer to fascia screws lacquered: MBE GmbH

Flowdrill Process
Flowdrills are polygonally ground carbidetipped tools. The Flowdrill
Countersunk screw with distance sleeve
presses against the thin metallic material with a relatively high rotational
speed and axial pressure. The generated heat makes the material soft
enough to push the Flowdrill through the workpiece thus forming a
hole. The material which is mainly displaced in process direction forms
a bushing at the same time. The length of the bush can be 3 to 5 times
the original material thickness. In the case of threaded fasteners higher
pullout strength can be obtained due to the larger contact area of the
screws. The “flat/short” Flowdrill type is used for ALUCORE ®. These
drills are suitable for thin materials and remove protruding material from
the panel surface at the same time.

Supplier for Flowdrill tools

Flowdrill
Fließformwerkzeuge GmbH
www.flowdrill.com

Flowdrill

Edition 2  ALUCORE® Processing and Technical Data  GB 17

 JOINTING / FIXING TECHNIQUE
Suppliers for stud welders and
studs
HBS Bolzenschweiß-Systeme
GmbH & Co. KG
www.hbs-info.com
Heinz Soyer
Bolzenschweißtechnik GmbH
www.soyer.de
Further suppliers
www.schweissbolzen.de
www.i-vt.de
www.schmeck-schrauben.de
www.thomas-welding.com
18
Stud welding with tip ignition on mill-finished ALUCORE ® surfaces
By applying a force without the use of auxiliary material, studs and pin-
type parts are welded to the carrier material by means of an electric
arc. Capacitor-discharge stud welding with tip ignition is suitable for
ALUCORE ® for sheets of a minimum thickness of 1 mm. Studs and pins
are used for various types of join.
Stud diameter: 3-8 mm
Material: AlMg Alloy
Ignition Creating a fusion zone Welding
Process:
1. The capacitor battery is charged.
2. A spring in the welding gun moves the stud (with tip) towards the
workpiece.
3. The tip comes into contact with the workpiece and thereby closes
the circuit. The rapidly increasing current causes the ignition tip to
melt instantaneously, thus initiating the electric arc.
4. Stud and workpiece are welded together.
5. When the stud touches the workpiece the electric arc is extinguished,
the fusion zones on stud and workpiece are joined and solidify.
Owing to the highly dynamic process, the selection of the setting
parameters is particularly important. The appropriate combination of
the mechanical properties of the spring force and the air gap and the
setting parameters of the capacity and the charging voltage is decisive
for obtaining repeatable results.
Stud welding offers the following advantages:
- low thermal effect on stud and ALUCORE ® panel
- fastening method without forming a hole, the panel is not weakened,
sealed connection
- welding from one side without counter support
- suitable for cover sheets with a minimum thickness of 1 mm
- fast working cycle
Edition 2  ALUCORE® Processing and Technical Data  GB
JOINTING / FIXING TECHNIQUE

GLUEING
Tapes / velcro tapes
Double-sided tapes (such as the 3M-VHB high capacity jointing systems)
can be used for the above applications with low tensile or transversal
strength requirements. Velcro tapes are available for detachable joints,
for example SCOTCHMATE or tapes marketed under the Dual Lock
trademark (3M, www.3m.com).

Adhesive sealing compounds

For high-strength and elastic connections we recommend the following
one-component adhesive sealing compound: Sika Bond-T2 (polyurethane
base), Sika GmbH (www.sika.de).
For outdoor use, this adhesive can be used for fastening parts of minor
static importance.

Metal adhesives / universal adhesives

 

Voluma system
For indoor use, trade fair/exhibition stand structures and machines, most
metal or universal adhesives are suitable.
Important:
Please observe the manufacturer’s instructions regarding the application
and use of adhesives / tapes. Laminating one side of ALUCORE ® panels
to other materials may result in deformation of the laminates (differing
expansion / bimetal effect).

Irus system
CLAMP CONNECTIONS
Clamp connections incorporating aluminium or plastics are particularly
suitable for ALUCORE ®. They generally consist of two parts with the
clamping effect achieved by bolting. Various designs of clamping ele-
ment are used for display and store fitting purposes (no outdoor use).

Supplier
Klemetric system
KlemProducts ® Gesellschaft für Werbemittel mbH
www.klemproducts.com
Voluma system
MERO Raumstruktur GmbH & Co. KG Ausstellungssysteme
www.mero.de
Irus system
Irus-System
www.irus-system.com

Any suitable connection or shock-resistant frame can easily be made with

aluminium sections. For fascia cladding applications special aluminium
sections are provided for clamp connections. For further information
on ALUCORE ® special sections and types for fascia claddings please
ask for the respective documentation.

Edition 2  ALUCORE® Processing and Technical Data  GB 19

 SURFACE TREATMENT

LACQUERING
Overlacquering of stovelacquered ALUCORE ® surfaces of polyester
lacquer quality (panels not exposed to weather conditions)
Aluminium treatment and priming carried out at the factory in a conti-
nuous process with continuous quality control is advantageous to the
overlacquering of the stove-lacquered ALUCORE ® surface.
ALUCORE ® overlacquering procedure
- Pre-cleaning of the panels using methylated spirit
- Grinding the surfaces with wet abrasive paper (grain size 360)
- Removing grinding dust with a lintfree cloth moistened with spirit
- For the top coat, please follow the instructions of the top coat supplier

Lacquering of mill-finish ALUCORE ® surfaces

The composition of lacquer coating for millfinish ALUCORE ® is basically
the same as for mill-finish aluminium surfaces. However, it is advisable
to be familiar with coating systems and materials as well as working
methods for aluminium.

Additional information
For general information on painting, lacquering and coating of aluminium we
recommend leaflets on „02, 03, 012, 015 surfaces” issued by Gesamt-
verband der Aluminiumindustrie e.V. (GDA) www.aluinfo.de.

PRINTING
Printing on ALUCORE ® surfaces in polyester lacquer quality
Stove-lacquered ALUCORE ® panels are well suited for printing. Prior to
printing, please make sure to remove the protective foil and clean the
surface with a lintfree cloth moistened with ethyl or isopropyl alcohol.
The alcohol must not be poured directly onto the panel. The lacquer coat
can be damaged by the use of methylated spirit. About 10 to 15 minutes
should be left between cleaning and printing.

Practice has shown that even within a given specification of stove-lacquer

paint and printing ink there may be variances, and in view of this it is re-
commended that in the case of each particular application the adhesion
properties of the selected printing ink should be tested.

LAMINATING
ALUCORE ® can be laminated (manually or by machine) with cast or
calendered selfadhesive foils. The varnish does not come off when
changing the foils.

20 Edition 2  ALUCORE® Processing and Technical Data  GB

CLEANING AND MAINTENANCE

GENERAL
Expert and regular cleaning not only maintains the aesthetic and repre-
sentative finish of stove-lacquered surfaces but also maintains their
quality through the removal of dirt and aggressive deposits.

Cleaning intervals depend on local environmental conditions and the

resulting amount of soiling. Surfaces should be cleaned either manually
or with a suitable cleaning device from top to bottom. Please do not
use any abrasive pads on lacquered surfaces. We recommend that the
cleaning agent be tried on an unobtrusive part of the object to be cleaned
to check whether the surface is affected.

Do not clean hot surfaces (> 40° C) as the quick drying process may
cause blemishes.

CLEANING AGENTS
Please observe the manufacturer’s cleaning and safety instructions! For
further information such as addresses of approved and recommended
cleaning companies and a list of neutral cleaning agents for organically
coated or anodized aluminium components, please contact Gütege-
meinschaft Reinigung von Fassaden e.V. (GRM) www.grm-online.de.

NON-SUITABLE CLEANING AGENTS

Please do not use any powerful alkaline cleaning agents such as potas-
sium hydroxide, soda, caustic soda or any powerful acidic products or
heavily abrasive scouring agents or lacquer-dissolving cleaning agents.

Edition 2  ALUCORE® Processing and Technical Data  GB 21

 TECHNICAL DATA

ALUCORE ® ALUCORE ® base

Standard thickness [mm] Unit 6 10 15 20 25 9.5 14
Cover sheet thickness, front side [mm] 1.0 0.5
Cover sheet thickness, rear side [mm] 0.5 0.5 1.0 1.0 1.0 0.5
Weight [kg/m²] 4.7 5.0 6.7 7.0 7.3 3.5 3.7

Technical properties
Section modulus W [cm³/m] 2.5 4.5 13.1 18.1 23.1 4.3 6.5
Rigidity E∙J [kNcm²/m] 7 100 21 900 75 500 138 900 221 600 15 600 35 000
Alloy of cover sheet EN AW-5005A EN AW-5005A (AIMg1) EN AW 5005A
(accord. to EN 485-2 / EN 1396:2007) (AIMg1) H28 / H48 (AIMg1)
H22 / H42 (H22 / H42) H22 / H42
Modulus of elasticity E [N/mm²] 70 000 70 000
Tensile strength of cover sheets Rm [N/mm²] ≥ 125 ≥ 185 (125) ≥ 125
0.2% Proof stress R p0,2 [N/mm²] ≥ 80 ≥ 160 (80) ≥ 80
Elongation A 50 [%] ≥5 ≥ 2 (5) ≥5
2.4 mm/m at 100º C
Linear thermal expansion α 2.4 mm/m at 100º C temperature difference
temperature difference

Core
Bare compressive strength [N/mm²] approx. 2.5 approx. 1.5
[inch] 3/8 1/2
Cell size
[mm] (9.5) (12.7)

Surface
both sides polyester platinum white
Lacquering or fluoropolymer lacquer (e.g. PVDF),
one or both sides
both sides mill finish
Brilliance (standard) [%] 25 – 40
Hardness (pencil hardness) HB-F

Acoustical properties
Sound absorption factor αs 0.05 0.05
Air-borne sound insulation index
Rw [dB] 21 21 22 23 25 approx. 20
(accord. to ISO 717-1, ISO 140-3)

Thermal properties
Thermal conductivity (depends on total
λ [W/mK] 0.95 1.35 1.78 2.25 2.70 1.01 1.30
panel thickness incl. cover sheets)
Thermal resistance R [m²K/W] 0.0063 0.0074 0.0084 0.0089 0.0093 0.0094 0.0107
Heat transition coefficient U [W/m²K] 5.67 5.64 5.61 5.59 5.58
Temperature resistance [ºC] -40 to +80 -40 to +80

22 Edition 2  ALUCORE® Processing and Technical Data  GB

INFORMATION

INFORMATION (please request)

-- ALUCORE ® product information

-- ALUCORE ® original samples of standard surfaces

Our brochures are also available at

www.transport-industry.com DOWNLOADS

Edition 2  ALUCORE® Processing and Technical Data  GB 23

Boundless possibilities.

01/02/2017 Edition 2  ALUCORE® Processing and Technical Data  GB

3A Composites GmbH
Alusingenplatz 1
78224 Singen, Germany
Phone + 49 7731 - 941 2254
transport-industry@ 3AComposites.com
www.transport-industry.com